Oil Filtration & Varnishing Plants
Oil Filtration Plants
Transformer Oil Filtration And Dehydration
Oil Cleaning (Hydraulic Oil, Coolant etc.)
Transformer Oil Regeneration Reclamation Plant
Varnishing Machines
Trickle Varnishing
Vacuum Impregnation
Special Purpose Machines
Transformer
We supply different types of plants for the purification / up-gradation of the mineral Transformer Oil to standard specifications. These plants cover entire range of low, high and extra high voltage equipment such as transformers. These Plants are designed and supplied to suit specific requirements of customers.
The plants are available in various designs and capacities to carry out following operations:
Removal of all suspended particles such as dust, rust, scales, colloidal carbon oxidation sludge etc. up to < 1 micron. Degassing and Dehumidification of Transformer Oil under vacuum. Circulation of heated Oil and Filling of treated oil in Transformer tank. De-acidification by evaporation and adsorption method. Our single stage plants are capable of attaining following oil parameters in 3-4 passes and Two Stage Plants in 1-2 passes :
NO
Parameters
Before Filtration
After Filtration
1
Break Down Voltage with 2.5 mm Electrode Gap.
25 kV
50-70 kV.
2
Moisture Removal
50-100 ppm
Up to 5 ppm.
3
Neutralization Value
0.5 mg of KOH/gm of oil
< 0.1 mg of KOH/gm of oil
4
Particle size (Filter Fineness)
Visible to naked eye
Up to < 1 micron
5
Gas Content
<10% by volume
< 0.1% by volume
Portable Type
Mobile type
Product Highlights
1. Designed And Supplied To Suit Customer's Requirement
2. Plants With Minimum And Easy Maintenance
3. Low Operating Cost Due To High Vacuum Filtration With Rotary Oil Sealed Pumps
4. Plants Are Also Suitable For Hydraulic Oil, Turbine Oil, Etc.
Major Components
Oil Transfer & Circulating System
Mainly consists of inlet pump (Gear type positive displacement), Outlet pump (positive displacement Gear type or Multistage Centrifugal) and necessary valves & piping to ensure easy operation and maintenance. Complete system is vacuum tight to have a leak -proof operation.
Heating System
It is capable of heating the oil 25 o C to 80 o C. It contains insulated heat exchanger with indirect low watt density (Less than 2 W/cm2) bobbin type electric heaters. Oil temperature is controlled with thermostat. Suitable oil distribution system is provided to ensure uniform flow of oil over heaters.
Filtration System
It is suitable for removing suspended particles such as colloidal carbon, oxidation sludge, dirt, rust, and scales up to < 1 micron. It consists of PRE FILTER and FINE FILTER.
Pre Filter
It is a metallic strainer with magnet. It removes magnetic and coarse suspended particles and to protect inlet pump from damage due to abrasion.
Fine Filter
Removes all suspended particles up to < 1 micron. Filter Elements are either non-hygroscopic moulded cellulose cartridges or cleanable (with reverse airflow) edge type filter candles. Filter cartridges are easily replaceable. Additional Intermediate filter can be provided to increase life of fine filter.
Degassing & Dehydration Chamber
It is designed to remove large portion of dissolved impurities (Including Moisture) from oil. Rasching ring trays and oil dispersing system are provided to have sufficient exposure of oil to vacuum during filtration. Oil level is controlled with float switch.
Vaccum System
Rotary oil-sealed vacuum pump or combination of Mechanical Booster Pump and Rotary oil-sealed pump is provided to get proper working vacuum during filtration. Necessary valves for easy operation and maintenance of the plant.
Control Panel
Centralized control panel is provided with necessary contactors, overload relays, fuses, push buttons, indicating lamps, main switch etc. for easy and safe operation of the plant.
Optional Items
Ionic Reaction Column for acidity removal.
Transformer Evacuation System.
Filter Press as an intermediate filter to increase the cartridge life.
Additional Instrumentation such as Temperature Indicating Controller, Flow Meter,
On-line Oil Testing Equipment.
Transformer Oil Filtration & Dehydration(Single Stage)
These plants are designed for filtration and dehydration of Power and Distribution Transformers and oil in tank. These plants can also be used for hot oil circulation in transformers and transformer drying. These plants are available in Series S (Stationery Units), Series P (Units on Castors) and Series M (Units on Trailer)
Technical Specifications
Flow Rate - LPH
600
1200
2400
4500
6000
Heater Capacity - kW
18
45
63
81
Technical Specifications
1-V-060
1-V-120
1-V-240
1-V-450
1-V-600
Single Stage Rotary Oil sealed vacuum Pump
100 LPM
300 LPM
500 LPM
1000 LPM
2000 LPM
Total Power Required
7.5 kW.
20 kW.
50 kW.
70 kW.
96 kW.
Fine Filter Elements Moulded Cellulose
2
4
9
18
27
Filter Fineness
3 / 0.5 µ
Dimensions in Mtrs
Stationery Unit, W/L/H
0.6/0.9/1.4
0.8/1.2/1.5
1.0/1.8/1.6
1.2/2.0/1.7
1.2/2.4/1.8
Unit on Castors, W/L/H
0.6/0.9/1.6
0.8/1.2/1.7
1.0/1.8/1.9
1.2/2.0/2.0
1.2/2.4/2.1
Unit on Trailer, W/L/H
1.2/1.4/2.1
1.4/1.7/2.2
1.6/2.2/2.4
1.8/2.4/2.6
1.8/2.8/2.6
Max Oil Content in
Transformer - Ltrs.
1000
2500
7500
20000
35000
These plants work on high vacuum and are designed for filtration and dehydration especially of Power Transformers at site.
Technical Specifications
2-V-060
2-V-120
2-V-240
2-V-500
2-V-800
Flow Rate - LPH
600
1200
2400
5000
8000
Heater Capacity - kW
9
27
54
81
108
Roots pump backed by Two Stage Rotary Oil sealed vacuum Pump
60 M3 / Hr.
100 M3 / Hr
200 M3 / Hr.
400 M3 / Hr
600 M3 / Hr.
Total Power Required (KW)
10.5
29
60
87
115
Fine Filter Elements Moulded Cellulose
2
4
9
18
27
Filter Fineness
3 / 0.5 µ
Dimensions In Mtrs.
Stationery Unit-S W/L/H
0.6/0.9/1.4
1.0/1.6/2.0
1.0/2.1/2.0
1.2/2.5/2.0
1.2/2.6/2.2
Unit on Castors-P W/L/H
0.6/0.9/1.6
1.0/1.6/2.2
1.0/2.1/2.2
1.2/2.5/2.2
1.2/2.6/2.6
Unit on Trailer-M W/L/H
1.2/1.4/2.1
1.0/1.6/2.6
1.0/2.1/2.6
1.8/2.5/2.8
1.8/2.8/3.0
Max Oil Content in Transformer - Ltrs.
1000
2500
10000
25000
50000
Guidelines for Selection of plant as per requirements
Basic Design: Single Flow Pass Design (Two Stage Plant) is suitable for filtration of high voltage transformers and Multiple Flow Pass design (Single Stage Plant) is suitable for low and medium voltage Transformers.
Flow Rate:
is decided by the quantity of oil to be filtered and the time available for filtration.
Optional Items can be added depending on the need of filtration, oil purification such as Ionic Reaction Column for acidity removal, Filter Press for more dirt accumulation, Transformer Evacuation System for filtration and oil filling under vacuum.
Stationary / Portable / Mobile plants are selected according to place for filtration. Stationary plants are useful for transformer supplier / repairers who carry out filtration in factory. Mobile / Portable plants are suitable for filtration at site. Portable plants are more suitable when: a) the number of transformers to be filtered is large and, b) the location of transformers is difficult to reach with conventional trailer mounted machines.
Oil Cleaning System Suitable For
Hydraulic Oil, Cutting Oil, Coolant etc
Oil cleaning systems are custom built to suit the specific requirement of customer. Normally our plants are rated for filtration of 1, 3, & 5 micron and dehydration up to 20, 50 & 200 ppm. However, plants with particular filtration rating can be offered. It is portable mounted on frame with castor wheels and will be suitable for on line oil cleaning. It can be permanently fitted on the oil tank of the system for continuous removal of contaminants and maintaining the oil quality. The system is suitable for removal of suspended particles and free moisture separation. The system normally consists of stage wise separation of contaminants. It is normally a combination of our standard modules, developed for removal of specific contaminants e.g. Spirafuge for coarse dirt filtration and free water separation. Magnetic filter for ferrous particles filtration, Coalescer for free and emulsified water separation and Vacuum Dehydration for fine moisture removal. Systems are compact in design and are easy for operation and maintenance. Systems do not require any attendant during filtration. The system is generally as per the schematic diagram and will contain some of the following components.
Major C
omponents
1) Pre – Filter:
In this major portion of coarse dirt is removed. Depending upon the type of contaminants pre-filtercan be chosen.
Magnetic Strainer:
It is a magnetic strainer to remove magnetic and coarse particles from oil.
Magnetic Separator :
It is designed to remove magnetic particles from oil. Disc Magnets are mounted on a shaft driven by geared motor at very slow speed. Lower parts of the discs are dipped in the oil and upper parts are provided with wiper / scrubber for removing particles collected on magnets. It is specifically provided where ferrous contamination is more especially in case of cutting oils.
2) Intermediate Filter :
It is normally provided to increase the life of fine filter elements. Normally it is cleanable to reduce filter replacement cost.
Bag Filter:
It is a bag type filter to remove suspended particles up to 10 microns. It is provided to increase the life of the fine filter elements. It has large dirt holding capacity and can be cleaned easily for reuse.
Spirafuge:
It has Filter Element at centre and spiral oil path at the periphery of the chamber. Coarse dirt separates here because of centrifugal force developed by spiral oil motion. Dirt is collected at bottom because of vortex and on the walls of Filter Element. Filter Element can be cleaned by opening the drain valve during running or automatically by sensing backpressure developed by dirt accumulation. It is provided with pressure gauge for filter clogging indication.
3) Fine Filter :
It is provided to remove all suspended particles, up to 1 or 3 microns as per the requirement. It contains moulded cellulose filter elements of the required rating. These filters are normally provided in degassing chamber or in Coalescer or separate chamber. Gauge is provided to indicate the filter clogging.
Coalescer / Separator:
The dictionary definition of coalescence is “To grow together; to unite into one body or mass”. As applied to the technology of oil water separation, coalescence is usually accomplished by a first stage of fibrous media that allows oil to pass through but attracts and “stores” the emulsified water until these tiny particles unite, or coalesce, to become large droplet of water.
This free water is then released to a second stage utilizing water repellent media. It will be provided with water drain tank, for removal of separated water periodically. Pressure gauge will be provided to indicate the clogging of filter.
Centrifugal Filter:
In centrifugal Filter, oil passes through a rotor spinning at high speed so that particles in the oil are deposited on the inner wall of rotor to form a dense cake. It is particularly more suitable for permanent fitting on the oil tank. It has more dirt holding capacity as compared to normal depth filter of fine micron rating. Centrifugal separation is most suitable way to remove small hard metallic particles.
4) Vacuum Dehydrator:
It is provided to remove moisture from oil to the level of 50 ppm or less where water contamination is critical. It is M.S. fabricated chamber with shower arrangement, rasching ring tray, sight glass, float switch and vacuum pumping system. The oil dispersed while passing through fine filter will be sprayed on rasching ring tray to have an exposure of oil film to vacuum, because of which moisture removal rate will be increased. Degassing Chamber will be evacuated with rotary oil sealed vacuum pump, moisture trap, valves etc.
5) Oil Transfer And Circulation System:
The plant will have two pumps for oil transfer and circulation. Both pumps will be positive displacement gear type, directly coupled with electric motor. The plant will have necessary valves and piping to ensure easy operation and maintenance as per the schematic diagram.
6) Control Panel:
Centralized control panel is provided for easy and safe operation of the plant as per requirement of customer.
7) Oil Testing Kit:
Oil testing kit suitable for measuring parameters such as Oil contamination (Patch test), Moisture content, Viscosity, Total Acid Number can be offered along with system.
Some of commonly used combinations are :-
Oil Reclaimation / Regeneration Plants
The reclamation of Transformer Oil is economically justifiable, cost effective and environmentally sounds. The reclamation is economically attractive because of increasing prices for both mineral and synthetic transformer coolants. The reclamation rejuvenates the transformer oil by eliminating contaminants formed due to entry of foreign particles, oxidation of oil and insulation deterioration, sludge formation, thermal cracking etc.
In our plants oil is reclaimed by heating, filtration, and free moisture removal by coalescer filters, activated fuller's earth treatment and vacuum dehydration.
The plant will consist of mainly two sections:
1. Fuller's earth treatment plant with free moisture separation facility
2. Oil filtration and dehydration plant
Both the plants will be as per the schematic diagrams and technical specification sheets attached herewith.
The plant will be suitable for Oil treatment as described below:
Oil is taken into the raw oil storage tank with the help of vacuum. Then is allowed to settle in the tank and dirt, free water (if any) is drained out. Oil is sucked with the inlet pump. Then it is heated by passing through heater tank and then passed through spirafuge and coalescer filter to separate coarse contaminants and free moisture present in the oil.
After removal of free moisture oil is passed through the activated fuller's earth tank to remove acids and impurities such as breakdown products arising in the use of oil. Fuller's earth is used before vacuum treatment to provide cleaner feed and to give an oil final polish.
Then this oil is passed through the fine filter and vacuum degassing and dehydration chamber to remove the maximum moisture and other contaminants to achieve required oil quality / parameters.
Arrangement can be made for acid and neutralization treatment in the raw oil storage tank.
One more blending tank can be provided for blending the oil for passivation.
In case you need any other treatment to be given to oil, we can offer you the plant with the same.
TIMachine Type
Trickle varnishing machine suitable for stator (field)& rotors (armatures) of small electric motors, auto-electrical, kitchen appliances, fans etc.Machine is suitable for production up to 500 jobs per shift. For more production rate conveyorised machine can be offered.
Impregnating Machine (Batch Type)
Trickle impregnating machine is suitable for varnishing of stators & rotors of electric motors (1 & 3 Phase).
Available in one, three & six station model.
Economical for production up to 150 pieces per shift.
Vacuum Impregnation Plant
Technical Specifications
IMPREGNATION CYCLE Vacuum / Pressure Impregnation Plant is designed for varnish impregnation to be carried out in following steps and will be generally as per the schematic diagram attached.
1. Pre-heating the jobs in either Impregnation Chamber or Oven.
2. Evacuation of Impregnation Chamber (after putting the jobs) to make the voids in the jobs clear
and drying of jobs for specific time & required temperature / vacuum.
3. Induction of impregnant (Varnish) in the Impregnation Chamber from impregnant Tank to submergethe jobs in it.
4. Pressurize the Impregnation Chamber with dry air or nitrogen to fill the voids with impregnant.
5. Return the varnish to impregnant Tank.
6. Evacuate the Impregnation Chamber and cure the jobs either in impregnation Chamber or in Oven for specific time.
Major C
omponents
Impregnation Chamber
· Working Volume: 100 Ltrs to 5000 Ltrs.
· Material of construction: M.S. plates, bars, structural etc.
· Working Pressure: @ 4 kg/ cm2 & Vacuum: As per process requirement.
· Lid Opening: Screw Davit type for quick opening & closing.
· Chamber Dimensions: as per job Size and Quantity.
· Will be provided with: Oil Heating / cooling Jacket, Quick Clamping bolts, Stirrer, Neoprene Gaskets,
Sight glass, Illuminating Lamp, Pressure Safety Valve, Vacuum & Pressure gauges etc. as per thevarnish specifications.
Impregnant Storage T
ank
¨ Materi